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Finally getting to the deck core replacement on my F-26. So far all of the rotted deck core on the cabin top has been removed and starting prep for the new core to go in. I have someone doing the job for me as it's a bit out of my comfort zone. I have seen a lot of his work and it should come out really well once done. We are doing the cabin top first, then we will address the forward deck core. All of the deck hardware has been removed, very little or no caulking was found. All interior wood trim was removed, as I will be replacing the headliner once the deck is complete. I covered the cabin in plastic in case any resin finds its way into the cabin. I will post photos as the project moves forward. The top sides will be re-gel coated and a complete new non-skid pattern will be applied. Here's the initial core removal.

Thanks Tom,
from what I've learned so far, when you do your bridge, unless you have some good support under the deck I would do it in sections as once you remove a large section of deck and expose the lower layer of glass, it is a bit on the flimsy side. The bottom layer of glass is appx 1/8". The core on top of the cabin was 3/4" while the forward deck is 1/2". Learning a lot as this progresses.

The project is continuing to move forward, the area that had the core removed has been prepped and is ready to receive it's new core. It was dri-fit this week, waiting for it to warm up a bit to start closing this section up. I removed the Bow cleat, in preparation for starting that section next, and found that there was no bedding compound or caulk on the cleat. Now I know where most of the water got into the core on that section. The bolts were in pretty bad shape, glad I never needed a tow. I have a new 10" stainless cleat to replace it. Here's the next batch of photos

Last edited by MattSC on Sun Mar 10, 2013 9:35 pm, edited 1 time in total.

The cabin top is structurally completed, and came out really well. It's just waiting for it's new gelcoat. Sorry for the photo of the cabin top (the photo is the starboard front corner) as all of the working tools were placed on the cabin top before I could take a picture of it, but I'm really happy with it. We started on the bow section, which was pretty well saturated and soft. It looks like the softness might extend into the walkway on the outside of the cabin top, at least on the starboard side. It is being done in two sections so as to not make the deck too flimsy when working on it.

What I found pretty interesting, was that the cabin top had a complete thickness of 1". 1/8" glass, 3/4" core and 1/8" glass. The bow forward deck is 1/4" glass, 1/2" core and 1/4" glass for a complete thickness of 1".

The forward deck is structurally done, one more layer of glass then the fairing and filling can begin. For the first time I was able to stand on the forward deck without the mush underfoot, what a great feeling. Once this is set then we will continue down the deck between the cabin and gunnels, on both the starboard and port side and install new coring there as well. The main deck will be all new coring when completed.